Apparatus for producing a web substrate having indicia disposed thereon and elastic-like behavior imparted thereto

ABSTRACT

An apparatus for providing a printed and textured web substrate is disclosed. The apparatus has a printing apparatus and an apparatus for imparting elastic-like behavior. The printing apparatus has at least one rotatable ink roller for transferring an ink to the web substrate. The apparatus for imparting elastic-like behavior has a pair of intermeshing rollers capable of providing at least a portion of the web substrate with an elastic-like behavior.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/737,430, filed Dec. 16, 2063, now U.S. Pat. No. 7,410,683which is a continuation-in-part of U.S. patent application Ser. No.10/610,299, filed Jun. 30, 2003, now abandoned, which is acontinuation-in-part of U.S. patent application Ser. No. 10/324,661,filed Dec. 20, 2002, now abandoned.

FIELD OF THE INVENTION

This invention relates to web substrates and more particularly to suchweb substrates having an indicia printed thereon and wherein theinherent elongation properties of the web substrate may be modified.More particularly, the present invention relates to apparati andprocesses suitable for the manufacture of web substrates suitable forthe packaging of consumer products in which the web substrate isprovided with indicia thereon and is subsequently treated by mechanicaldeformation in which the resistive force exerted by the web material toan applied elongation force can be modified. The indicia printed uponthe web substrate may be positioned in registration with portions of theweb substrate in which the inherent elongation properties of the websubstrate have been modified.

BACKGROUND OF THE INVENTION

The term “flexible” is utilized herein to refer to materials that arecapable of being flexed or bent especially repeatedly such that they arepliant and usable in response to externally applied forces. Accordingly,“flexible” is substantially opposite in meaning to terms such as“inflexible”, “rigid”, or “unyielding”. Materials and structures thatare flexible therefore may be altered in shape and structure toaccommodate external forces and to conform to the shape of objectsbrought into contact with them without losing their integrity. Flexiblefilms of the type commonly available are typically formed from materialshaving consistent physical properties throughout the film structure,such as stretch, tensile and/or elongation properties.

A process known for forming flexible film web substrates havingdeformations formed thereon include the passing of a continuous webmaterial between a pair of matched forming rolls to form an intentionalpattern of deformations in the film. Illustrative publications dealingwith the state of the art with regard to continuous webs and filmmaterials having intentional patterns and deformations disposed thereonare detailed in U.S. Pat. Nos. 5,554,093; 5,575,747; 5,723,087;5,518,801; 5,156,793; 7,172,801 and 6,394,652.

Likewise, printed film materials can be produced by several processes. Afirst process for printing a web substrate is the use of a rotogravureprocess. A rotogravure process is a true “intaglio” (i.e., cut-in orsunken) printing process. Rotogravure processes print directly fromunconnected cells engraved into a plate cylinder. Ink is then applied tothe engraved areas and doctored, or wiped off, the smooth non-imageareas. The resulting inked image is then impressed onto the substrate tobe printed. Typical print cylinders in rotogravure processes aremachined, electroplated with copper, ground, and polished. The cellsholding the ink are not interconnected; therefore, a checkerboard or sawtooth pattern shows up around the print edges—a characteristic ofgravure printing. To overcome these deficiencies, very fine screen sizesare used to make the rough edges as inconspicuous as possible. Thecylinder's print areas are etched as microscopic cup-like cells whilenon-print areas remain untouched: the larger and bolder the copy, thelarger and deeper the etched cells. Fine tonal areas typically have asmaller cell size and depth. As would be known to those of skill in theart, inks suitable for use in a rotogravure process are fluid and havevery low viscosity.

A second process for printing web substrates involves flexographicmethods. Flexographic printing methods are methods of direct rotaryprinting that use resilient relief-image plates of rubber orphotopolymer materials. The plates are affixed to plate cylinders andare inked by a cell-structured ink metering “anilox” roll carrying afast drying fluid ink to plates that print onto virtually any substrate,absorbent or non-absorbent. An image is produced for every revolution ofthe printing plate cylinder. The printing plate cylinder is typicallysuitable for re-use with multiple designs depending upon the repeatpattern and web material width. Flexographic processes were developedprimarily for printing onto packaging substrates where materials arecommonly supplied in roll form for feeding into form/fill, overwrapping,bag making, and other continuous web processing machinery. As would beknown to those of skill in the art, flexographic printing processes useeither solvent or water-based low viscosity inks that dry very quicklybetween the print stations of a press.

Typical texturing processes for providing a printed web substrate withand elastic-like behavior can cause deformations in the printed surface,thereby obscuring any indicia disposed upon the web substrate.Particularly, the loss of branding indicia, consumer informationindicia, patent marking statement indicia, and the like upon suchpackaging by an texturing process is an undesirable effect.

Accordingly, it is desirable to provide for a textured and printedsubstrate wherein the benefits of an “elastic-like” behavior in thedirection of an applied elongation to the web substrate can be presentedinto such a material that does not obscure any indicia presentedthereon. As used herein, the term “elastic-like” describes the behaviorof web materials which, when subjected to an applied elongation, extendin the direction of applied elongation and when the applied elongationis released, the web materials return to a substantial degree to theiruntensioned condition. While such web materials exhibiting anelastic-like behavior would have a wide range of utility (such ascovering materials such as upholstery, wrapping materials for complexshapes, commercial packaging, and the like), they would be particularlywell suited for providing indicia-laden consumer packaging with anability to be gripped as well as reduce the amount of breakthrough whenthe packaging is handled by the consumer.

SUMMARY OF THE INVENTION

A preferred embodiment of the present invention provides for anapparatus for providing a printed and textured web substrate. Theapparatus comprises a printing apparatus and an apparatus for impartingan elastic-like behavior to the web substrate. The printing apparatuscomprises at least one rotatable ink roller and an ink sourcecooperatively associated and in fluid communication with each of the inkrollers. The ink source provides ink to the respective ink roller. Theink is transferable to the web substrate when the web substrate isproximate to the ink roller. The apparatus for imparting elastic-likebehavior comprises a pair of intermeshing rollers. A first of the pairof intermeshing rollers has a plurality of ridges and correspondinggrooves. A second of the pair of intermeshing rollers has a plurality ofregions of circumferentially extending ridges extending in a spacedrelationship about at least a portion of the second of the pair ofintermeshing rollers. Each of the plurality of regions ofcircumferentially extending ridges is separated by correspondinggrooves. The apparatus for imparting elastic-like behavior is capable ofproviding at least a portion of the web substrate with a plurality offirst regions and a plurality of second regions. A portion of the firstregions extend in a first direction while the remainder of the firstregions extend in a second direction perpendicular to the firstdirection thereby intersecting one another. The first regions form aboundary completely surrounding the second regions. The second regionscomprise a plurality of raised rib-like elements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of an exemplary printing and apparatus, forimparting elastic-like behavior of the present invention;

FIG. 2 is a sectional view of an alternative web printing and apparatusfor imparting elastic-like behavior;

FIG. 3 is a sectional view of another alternative embodiment of anexemplary web substrate printing and apparatus for impartingelastic-like behavior;

FIG. 4 is a sectional view of yet another alternative embodiment of anexemplary web substrate printing and apparatus for impartingelastic-like behavior;

FIG. 5 is a perspective view of a preferred apparatus used to provideweb materials of the present invention with elastic-like behavior;

FIG. 6 is a perspective view of an exemplary surface suitable for apreferred apparatus for providing elastic-like behavior to a websubstrate;

FIG. 7 is a plan view of an exemplary consumer products packagingembodying the web material having indicia and an elastic-like behaviorimparted thereto;

FIG. 8 is an expanded view of the region labeled 8 in FIG. 7; and,

FIG. 9 is a sectional view of an alternative web substrate printing andapparatus for imparting elastic-like behavior.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates an embodiment of an apparatus for printing andimparting elastic-like behavior 10 in accordance with the presentinvention. As shown, the apparatus for printing and impartingelastic-like behavior 10 can be provided with an exemplary rotogravureprinting apparatus 12 and an exemplary apparatus for impartingelastic-like behavior 10. The exemplary rotogravure printing apparatus12 can be provided with at least one print station 16. However, one ofskill in the art will understand that preferably, a rotogravure printingapparatus 12 may be provided with a plurality of print stations 16, asmay be required by the needs of the printing process, the operator,and/or the final product. For example, an exemplary rotogravure printingapparatus 12 may comprise as few as one print station 16 or may compriseas many as eight print stations 16. For purposes of the instantinvention, it is irrelevant as to the number of print stations 16utilized with rotogravure printing apparatus 12, but rather it isrelevant that the number of print stations 16 be sufficient in order toprovide for the appropriate indicia to be applied to a web substrate 18that is printed by the rotogravure printing apparatus 12 of the instantinvention.

An exemplary (or in the alternative, each) print station 16 ispreferably provided with a cylindrical printing roller 20. By way ofexample, an ink may be provided to a cylindrical ink roller (not shown)by an ink applicator (not shown) that applies ink to the ink roller. Theink applicator may be, for example, a chambered doctor blade or otherconventional ink applying device. Typically, an ink roller is rotatablysupported by a support frame so that the ink roller is in contact withthe cylindrical printing roller 20. The support frame rotatably supportsthe cylindrical printing roller 20 adjacent to a cylindrical backingroller (not shown). A web substrate 18 to which the ink is to be appliedpasses through the nip formed between the cylindrical printing roller 20and a backing roller 22. The web substrate 18 may be supported ordirected by a plurality of support rollers 24. As would be known to oneof skill in the art, the rotogravure apparatus 12 may also include aconventional dryer (not shown) for drying the ink after it is applied tothe web substrate 18. A dryer may be provided at the exit of eachsucceeding print station 16 or over a plurality of print stations 16 asrequired by the operation or the operator. Similarly, a conventionalcooling apparatus (not shown), such as that disclosed in U.S. Pat. No.5,881,647, for cooling the web substrate 18 after it passes through thedryer can be provided as required

After unwinding a web substrate 18 from a wound parent roll 26, the websubstrate 18 is provided in contacting engagement with each successiveprint station 16 comprising the rotogravure printing apparatus 12 as maybe required to provide for the required indicia to be disposed upon websubstrate 18. After the required indicia are disposed upon web substrate18, the web substrate 18 is presented to the apparatus for impartingelastic-like behavior 14. An exemplary apparatus for impartingelastic-like behavior 14 is provided with a pair of intermeshing rollers28, 30. Intermeshing rollers 28, 30 are provided with a plurality ofintermeshing teeth (not shown). Intermeshing rollers 28, 30 are broughttogether under pressure to form the web substrate 18 of the presentinvention.

Turning to FIG. 5, the apparatus for imparting elastic-like behavior 14is provided with intermeshing rollers 28, 30. In an exemplaryembodiment, intermeshing roller 28 includes tooth regions 32 and groovedregions 36. The tooth regions 32 are preferably provided with aplurality of teeth 40 that mesh with teeth 42 of intermeshing roller 30.As shown in FIG. 6, the surfaces of intermeshing roller 28 andintermeshing roller 30 can be provided with one, or a plurality, ofdiscreet toothed regions 32, 34, respectively, and grooved regions 36,38, respectively, such that toothed region 32 of intermeshing roller 28is provided with teeth 40 that mesh with teeth 42 of intermeshing roll30. Thus, when a web substrate 18 is positioned between intermeshingroller 28 and intermeshing roller 30, the portions of the web substrate18 that are positioned within grooved regions 36 and/or toothed regions32 of intermeshing roller 28 and void region 76 of intermeshing roller30 remain undeformed. These regions correspond with the first regions 44of web substrate 18, shown in FIG. 8. The portions of the web substrate18 positioned between teeth 40 of toothed region 32 of intermeshingroller 28 and teeth 42 of intermeshing roller 30 are incrementally andplastically deformed creating rib-like elements 46 in the second regions48 of the web substrate 18. One of skill in the art would appreciatethat some materials are less able to withstand the high rate of strainexperienced in the process for imparting elastic-like behavior to theweb substrate. In such cases, it should be realized that alternatives toone or both of intermeshing rollers 28, 30 can be incorporated into theapparatus for imparting elastic-like behavior 14, such as, for example,belts, conveyors, or multiple rolls.

Turning to FIG. 6, an exemplary apparatus for printing and impartingelastic-like behavior 10 useful for the present invention provides for apair of intermeshing rollers 28, 30. For exemplary purposes only,intermeshing rollers 28, 30 can be provided with surfaces such as thoseshown. In this example, intermeshing roller 28 may be provided with aplurality of toothed regions 32 and a plurality of grooved regions 36that extend substantially parallel to a longitudinal axis runningthrough the center of the cylindrical intermeshing roller 28. Toothedregion 32 preferably includes a plurality of teeth 40. Further,intermeshing roller 30 may be provided with a plurality of teeth 42 thatmesh with teeth 40 on intermeshing roller 28. As a web substrate ispassed between intermeshing roller 28 and intermeshing roller 30, thevoid region 76 disposed upon the surface of intermeshing roller 30 willleave portions of the web substrate 18 unformed producing the firstregions 44 of the web substrate 18 of the present invention. Theportions of the web substrate 18 passing between toothed region 32 andtoothed region 34 will be formed by teeth 40 and 42, respectively,producing rib-like elements 46 in the second regions 48 of the websubstrate 18.

In a preferred embodiment of the present invention, the apparatus forimparting elastic-like behavior 14 preferably provides web substrate 18with an elastic-like behavior so that the web substrate 18 of thepresent invention may exhibit an initial elongation and partial recoverywhich results in the web substrate 18 not returning to its untensionedlength; that is, the web substrate 18 has undergone a degree ofpermanent set or deformation and has a new longer untensioned length.The web substrate 18 may exhibit an elastic-like behavior in response tosubsequent elongations of the web substrate 18 beyond the new longeruntensioned length.

Another elastic-like behavior that can be exhibited by web substrate 18is an elongation and recovery with a definite and sudden increase in theforce resisting elongation where this definite and sudden increase inresistive force restricts further elongation against relatively smallelongation forces. The definite and sudden increase in the forceresisting elongation is referred to as a “force wall”. As used herein,the term “force wall” refers to the behavior of the resistive force of aweb material during elongation wherein at some point in the elongationdistinct from the untensioned or starting point the force resisting theapplied elongation suddenly increases. After reaching the force wall,additional elongation of the web substrate 18 is only accomplished viaan increase in the elongation force to overcome the higher resistiveforce of the web substrate 18.

As shown in FIGS. 7 and 8, the web substrate 18 of the present inventionpreferably includes a strainable network 70 having at least two distinctand dissimilar regions comprised of the same material composition. Thefirst region 44 is preferably oriented substantially parallel to an axisof elongation such that it will undergo a molecular level deformation inresponse to an applied axial elongation in a direction substantiallyparallel to the elongation axis before a substantial portion of thesecond regions 48 undergoes any substantial molecular level deformation.As used herein, the term “substantially parallel” refers to anorientation between the two axes whereby the subtended angle formed bythe two axes or an extension of the two axes is less than 45°. In thecase of a curvilinear element, it may be more convenient to use a linearaxis which represents an average of the curvilinear element. The secondregions 48 initially undergo a substantially geometric deformation inresponse to an applied elongation in the direction substantiallyparallel to the axis. However, it should be readily realized that firstregions 44 may be aligned at any angular relationship to the axis ofelongation. It is not intended that the orientation of first regions 44be critical to the operation of the instant invention. Rather, it isimportant that first regions 44 be provided in such an orientation thatfirst regions 44 undergo a molecular level deformation in response to anapplied axial elongation before a substantial portion of the secondregions 48 undergo any substantial molecular level deformation. Thus,the first regions 44 may be oriented substantially or non-substantiallyparallel any axis of elongation.

In the preferred embodiment of the present invention shown in FIG. 8,the second region 48 is comprised of a plurality of raised rib-likeelements. As used herein, the term “rib-like element” refers to anembossment, debossment, or combination thereof, which has a major axisand a minor axis. Preferably, the major axis is at least as long as theminor axis. The major axis of the rib-like elements 46 are preferablyoriented substantially perpendicular to the axis of applied elongation.The major axis and the minor axis of the rib-like elements 46 may eachbe linear, curvilinear, or a combination of linear and curvilinear. Asused herein, the term “substantially perpendicular” refers to anorientation between two axes whereby the subtended angle formed by thetwo axes or an extension of the two axes is greater than 45°. In thecase of a curvilinear element, it may be more convenient to use a linearaxis which represents an average of the curvilinear element.

The rib-like elements allow the second regions 48 to undergo asubstantially “geometric deformation” which results in significantlyless resistive forces to an applied elongation than that exhibited bythe “molecular level deformation” of the first region 44. As usedherein, the “molecular level deformation” refers to deformation whichoccurs on a molecular level that is not discernible to the normal nakedeye; that is, even though one may be able to discern the effect ofmolecular level deformation (e.g., elongation of the web material), oneis not able to discern the deformation which allows or causes it tohappen. This is in contrast to the term “geometric deformation”. As usedherein, the term “geometric deformation” refers to deformations of theweb substrate 18 that are generally discernible to the normal naked eyewhen the web substrate 18 or articles embodying the web substrate 18 aresubjected to an applied elongation. Types of geometric deformationinclude, but are not limited to, bending, unfolding, and rotating.

Yet another elastic-like behavior that the web substrate 18 of thepresent invention may exhibit is an elongation and recovery with two ormore distinctive force walls. This type of elastic-like behavior wouldbe experienced if, for example, after reaching a first force wallsufficient elongation force was applied to overcome the first force walland continue to elongate the web substrate 18 until a second force wallwas encountered.

When the web substrate 18 of the present invention has multiple orstaged force walls, rib-like elements 46 in one or more of the secondregions 48 reach their limit of geometric deformation and becomeessentially co-planar with the material in the first regions 44, therebycausing the web substrate 18 to exhibit a first force wall. Furtherelongation of the web substrate 18 molecularly deforms the rib-likeelements 46 which have reached their limit of geometric deformation andsimultaneously geometrically deforms the rib-like elements 46 in theremaining second regions 48 until they reach their limit of geometricdeformation, thereby causing the web substrate 18 to exhibit a secondforce wall.

In yet another embodiment of the present invention, the web substrate 18exhibits at least two significantly different stages of resistive forceto an applied elongation along at least one axis when subjected to anapplied elongation in a direction substantially parallel to that axis.The web substrate 18 includes a strainable network having at least twodistinct regions. One of the regions is configured such that it willexhibit resistive force in response to an applied axial elongation in adirection substantially parallel to the axis before a substantialportion of the other region develops any significant resistive force tothe applied elongation. At least one of the regions has a surface pathlength which is greater than that of the other region as measuredsubstantially parallel to the axis while the web substrate 18 is in anuntensioned condition. The region exhibiting the longer surface pathlength includes one or more rib-like elements 46 that extend beyond theplane of the other region. The web substrate 18 exhibits a firstresistive force to the applied elongation until the elongation of theweb substrate 18 is sufficient to cause a substantial portion of theregion having the longer surface path length to enter the axis ofapplied elongation, whereupon the web substrate 18 exhibits a secondresistive force to further elongation. The total resistive force toelongation is higher than the first resistive force to elongationprovided by the first region 44.

Preferably, the first regions 44 have a first surface path length L1 asmeasured substantially parallel to the axis of elongation while the websubstrate 18 is in an untensioned condition. The second regions 48 havea second surface path length L2 as measured substantially parallel tothe axis of elongation while the web substrate 18 is in an untensionedcondition. The first surface path length L1 is less than the secondsurface path length L2. The first region 44 preferably has an elasticmodulus E1 and a cross-sectional area A1. The first region 44 producesby itself a resistive force P1 due to molecular level deformation inresponse to an applied axial elongation D. The second regions 48preferably have an elastic modulus E2 and a cross-sectional area A2. Thesecond regions 48 produce a resistive force P2 due to geometricdeformation in response to the applied axial elongation D. The resistiveforce P1 is significantly greater than the resistive force P2 so long as(L1+D) is less than L2.

Preferably, when (L1+D) is less than L2, the first region 44 providesfor an initial force P1 in response to the applied axial elongation Dsubstantially satisfying the equation P1=(A1×E1×D)/L1. When (L1+D) isgreater than L2, the first and second regions 44, 48 provide a combinedtotal resistive force PT to the applied axial elongation D satisfyingthe equation:

${PT} = {\frac{\left( {A\; 1 \times E\; 1 \times D} \right)}{L\; 1} + \frac{\left( {A\; 2 \times E\; 2 \times {{{L\; 1} + D - {L\; 2}}}} \right)}{L\; 2}}$

Preferably, the surface path length of the second region 48 is at least15% greater than that of the first region 44 as measured parallel to theaxis of elongation while the web substrate 18 is in an untensionedcondition. More preferably, the surface path length of the second region48 is at least about 30% greater than that of the first region 44 asmeasured parallel to the axis of elongation while the web substrate 18is an untensioned condition.

Preferably, the first regions 44 are substantially planar; that is, thematerial within the first region 44 is in substantially the samecondition before and after the formation step undergone by web substrate18. The second regions 48 include a plurality of raised rib-likeelements 46 that may be embossed, debossed, or provided as a combinationthereof. The rib-like elements 46 have a first or major axis 50 which issubstantially parallel to the transverse axis of the web substrate 18and a second or minor axis 52 which is substantially parallel to thelongitudinal axis of the web substrate 18. The major axis 50 of therib-like elements 46 is at least equal and preferably longer than theminor axis 52. Preferably, the ratio of lengths of the major axis 50 andminor axis 52 is at least about 1:1 or greater and, more preferably, atleast about 2:1 or greater.

The rib-like elements 46 disposed within second region 48 may beseparated from one another by unformed areas (essentially unembossed ordebossed) or simply formed as spacing areas. Preferably, the rib-likeelements 46 are adjacent one another and are separated by an unformedarea of less than 0.01″ as measured perpendicular to the major axis 50of the rib-like elements 46 and, more preferably, the rib-like elements46 are contiguous having no unformed areas between them.

Further, the depth and frequency of the rib-like elements 46 can also bevaried to control the available stretch of the web substrate 18 of thepresent invention. The available stretch is increased if for a givenfrequency of rib-like elements 46, the height or degree of formationimparted on the rib-like elements 46 is increased. Similarly, theavailable stretch is increased if for a given height or degree offormation, the frequency of the rib-like elements 46 is increased.

It should be realized that the particular web substrate 18 shown is anexample of an elastic-like web of the present invention. The presentinvention is clearly not limited to the geometric deformations shown inthe web substrate 18. Indeed, several alternative embodiments of websubstrates 18 of the present invention can have any shape, design, oroutcome of rib-like elements 46 as required to suit the intended purposeof the web substrate 18. Alternatively, the geometric deformation couldconsist of a more tuft-like structure.

In any regard, there are several functional properties that can becontrolled to the application of the present invention. The functionalproperties of the web substrate 18 are the resistive force exerted bythe web substrate 18 against an applied elongation and the availablestretch of the web substrate 18 before a force wall is encountered. Theresistive force that is exerted by the web substrate 18 against anapplied elongation is a function of the material (e.g., composition,molecular structure, orientation, and the like), cross-sectional area,and the percent of the projected surface area of the web substrate 18that is occupied by the first region 44. The higher the percent areacoverage of the web substrate 18 by the first region 44, the higher theresistive force that the web substrate 18 will exert against an appliedelongation for a given material, composition, and cross-sectional area.The percent coverage of the web substrate 18 by the first region 44 isdetermined in part, if not wholly, by the widths of the first region 44and the spacing between adjacent first regions 44.

Further, the available stretch of the web substrate 18 is determined bythe surface path length of the second region 48. The surface path lengthof the second region 48 is determined, at least in part, by the rib-likeelement 46 spacing, rib-like element 46 frequency, and depth offormation of the rib-like elements 46 as measured perpendicular to theplane of the web substrate 18. In general, the greater the surface pathlength of the second region 48, the greater the available stretch of theweb substrate 18.

In certain embodiments, it may be desirable to provide a web substrate18 having first regions 44, second regions 48, and/or rib-like elements46 that are registered relative to areas of the web substrate havingindicia 72 printed thereon. One of skill in the art would understandthat it may be desirable in certain consumer products 74 to provide forfirst regions 44, second regions 48, and/or rib-like elements 46 uponweb substrate 18 that are disposed in regions of lower print qualityupon web substrate 18. In certain consumer products 74, one of skill inthe art should understand that it may also be desirable to provide forfirst regions 44, second regions 48, and/or rib-like elements 46 uponweb substrate 18 in regions of web substrate 18 having no indicia 72printed thereon. However, one of skill in the art will understand thatthe degree of elastic-like behavior of the web substrate 18 of theinstant invention can be adjusted as required to provide for the amountof elastic-like behavior necessary in order to accommodate the needs ofthe consumer product 74 contained within the printed and textured websubstrate 56 bound thereabout and still provide for the increasedability of the consumer product 74 to be easily gripped and reduce theamount of breakthrough when the consumer product 74 is handled. Thisincludes providing first regions 44, second regions 48, and/or rib-likeelements 46 in regions of web substrate 18 having a high degree, ornumbers, of indicia 72 printed thereon and yet not obscure the indicia72.

Further, one of skill in the art would understand that either, or bothof, intermeshing rollers 28, 30 could be provided with a plurality ofholes or conduits that are in fluid communication with an ink to bedisposed upon web substrate 18. In this exemplary embodiment, it wouldbe possible to simultaneously dispose indicia 72 upon web substrate 18while web substrate 18 is being processed by the apparatus for impartingelastic-like behavior 14. Processing web substrate 18 in this mannercould facilitate the deposition of ink upon the web substrate 18 in theinterstitial regions disposed between individual rib-like elements 46and may further increase the quality of indicia 72 disposed upon websubstrate 18. Alternatively, as shown in FIG. 9, either, or both, ofintermeshing rollers 28, 30 could be put in surface contact with an inksource, such as an ink roller, in which the ink is deposited onto thepeaks of the ridges of the intermeshing rollers 28, 30. The ink is thendisposed upon the web substrate 18 while passing through the apparatusfor printing and imparting elastic-like behavior 10. It should berealized that these processes could also be used to print on non-wovensor other materials. In addition to printing ink, the processes disclosedherein could be adapted by one of skill in the art to print or depositother materials, such as lotions or glue that enhance the materialaesthetics or performance.

Returning again to FIG. 1, the web substrate 18 having indicia 72 andfirst regions 44, second regions 48, and/or rib-like elements 46disposed thereon may then be wound upon a second parent roll 54. At theuser's discretion, the second parent roll 54 containing the printed andelastic-like, structurally modified web substrates 56 may be storeduntil needed for a manufacturing process 58. When the printed andelastic-like, structurally modified web substrate 56 produced by thepresent invention is required by the manufacturing process 58, it may beunwound from second parent roll 54 and directed towards manufacturingprocess 58, as required.

The apparatus for imparting elastic-like behavior 14 could be locatedprior to the rotogravure printing apparatus 12, between rotogravureprinting apparatus 12 and a cooling apparatus (not shown), or between acooling apparatus and second parent roll 54 and/or intermediate parentroll 62. In some cases, the heat imparted to the web material 18 duringthe printing and/or drying steps could improve the ability to impart theelastic-like behavior to the web substrate 18, and it could improve theaesthetics or performance of the textured portion of the web substrate18. As shown in FIG. 2, an alternative apparatus for printing andimparting elastic-like behavior 10A of the instant invention can providerotogravure printing apparatus 12 and the apparatus for impartingelastic-like behavior 14 as separate and isolated steps. In such anapplication, the web substrate 18 is unwound from a wound parent roll 26and provided to a plurality of print stations 16. Each print station 16provides for at least a portion of the desired indicia upon websubstrate 18. Upon the completion of sufficient processing by printstation (or stations) 16 as required, the printed web substrate 60 canthen be wound upon intermediate parent roll 62. Then, as required, theintermediate parent roll 62, having printed web substrate 60 convolutelywound thereabout, can be separately processed by apparatus for printingand imparting elastic-like behavior 10 to provide for printed andtextured web substrate 56 as described supra. Printed and elastic-like,structurally modified web substrate 56 can be then wound about secondparent roll 54 and disposed as required to process 58. Alternatively,the printed web substrate 56 can be directed immediately to anymanufacturing process 58 as required by the needs of the end user.

FIG. 3 shows an exemplary apparatus for printing and impartingelastic-like behavior 10C. In the apparatus for printing and impartingelastic-like behavior 10C, a web substrate 18 is unwound from a woundparent roll 26 and presented to flexographic printing apparatus 64. Theflexographic printing apparatus 64 comprises a central impressioncylinder 66 surrounded by a plurality of printing units 68. Thus, theweb substrate 18 is applied to the surface of central impressioncylinder 66 and rotated about a longitudinal axis of central impressioncylinder 66 so that web substrate 18 progresses from a first printingunit 68 toward succeeding printing units 68 disposed about the peripheryof central impression cylinder 66. Each printing unit 68 can be coatedwith the appropriate ink necessary to provide indicia 72 that conveysthe branding information or other desired information necessary upon afinally printed web substrate 60. In one embodiment, the ink is appliedto a printing unit 68 by slot coating. Thus, by way of example, a firstprinting unit 68 disposed about central impression cylinder 66 can applya first color to web substrate 18 and succeeding printing units 68 canapply additional colors as required to web substrate 18 as web substrate18 passes between each individual printing unit 68 and centralimpression cylinder 66.

As known to those of skill in the art, each printing unit 68 may beprovided with a plurality of printing plates that are disposed upon theexterior of each printing unit 68. Typically, a printing plate isprovided with numerous small raised portions that transfer ink from anink roller to the web substrate 18 in passing engagement thereto.Typically, the raised portions of the printing plate are non-uniform inshape and correspond to the desired image for indicia to be printed onthe web substrate 18. The raised portions on the printing plate may beformed via a photosensitive etching process in which portions of theprinting plate are selectively exposed to radiation with the unexposedportions being subsequently removed via an etching agent, thus leavingthe raised portions behind. Typically, the total thickness of a printingplate is approximately ⅛″ to 1/16″. However, those of skill in the artwill understand that the formation of raised portions of the printingplate suitable for use with each printing unit 68 may be formed withother processes as is known to those of skill in the art.

As shown in FIG. 7, indicia 72 may comprise information typically foundupon consumer product packaging. By way of non-limiting example, indicia72 may comprise a branding signal. Exemplary, but non-limiting brandingsignals, may include, brand information (i.e. brand names—trade names ortrademarks including generic or descriptive language), productidentification information, brand logos (i.e., brand names or brand logothat are normally associated with the primary product being sold or witha secondary product such as indicia associated with a particular productor product line. The brand logo may include any combination of words,symbols, pictures or other graphic or textual elements), patent markingstatements, roll equivalency information, regulatory information,consumer product information (i.e., texture, absorbency, softness,caliper, biodegradability, hygiene, anti-microbial benefits, luxury,scent, moisturizing qualities, strength, and combinations thereof),packaging art work, as well as other visual representations orcommunicative indicia (i.e., including, but not limited to: brands,logos, brand logos, brand names, words, symbols, pictures, trademarks,graphics, text, product samples, advertising information, letters,messages, and combinations thereof), or other information that mayindicate a value or may provide value to the overall packaging.

Returning again to FIG. 3, after all necessary inks are applied to websubstrate 18 to form printed web substrate 60 to provide for indicia 72,the printed web substrate 60 can be provided with an elastic-likebehavior by the apparatus for imparting elastic-like behavior 14, asdescribed supra. The apparatus for printing and imparting elastic-likebehavior 10 can provide printed web substrate 60 with a plurality offirst regions 44 surrounding a plurality of second regions 48 havingrib-like elements 46 disposed therein. The apparatus for impartingelastic-like behavior 14 could be located prior to the flexographicprinting apparatus 64, between flexographic printing apparatus 64 and acooling apparatus (not shown), or between a cooling apparatus and secondparent roll 54 and/or intermediate parent roll 62. In some cases, theheat imparted to the web material 18 during the printing and/or dryingsteps could improve the ability to impart the elastic-like behavior tothe web substrate 18, and it could improve the aesthetics or performanceof the textured portion of the web substrate 18.

After providing the printed web substrate 60 with the required rib-likeelements 46 either in registration or out of registration with anyindicia 72 disposed upon web substrate 18 by the flexographic printingapparatus 64, the resulting printed and elastic-like, structurallymodified web substrate 56 can then be wound into a second parent roll 54for storage as required by the end user. Any registration requirementsor needs of the rib-like elements 46 with any indicia 72 provided uponweb substrate 18 can be provided to meet the needs of the consumer,consumer packaging, packaging operations or process as required. In somecircumstances, it may be desirable to provide for rib-like elements 46in regions of less indicia 72 upon web substrate 18. However, it shouldbe clearly realized that rib-like elements 46 can be disposed upon anyregion of web substrate 18 having indicia 72 disposed thereon withoutaffecting the overall quality and appearance of the final consumerproduct 74. Upon a defined need of the printed and elastic-like,structurally modified web substrate 56 disposed about second parent roll54 (i.e., manufacturing process 58), the printed and elastic-like,structurally modified web substrate 56 can be then utilized bymanufacturing process 58 as required. In a preferred embodiment,manufacturing process 58 utilizes the printed and elastic-like,structurally modified web substrate 56 as an overwrap for a plurality ofconsumer products 74.

Alternatively, as shown in FIG. 4, the printed web substrate 60 canalternatively be wound into intermediate parent roll 62. Upon a definedneed of a printed and elastic-like, structurally modified web substrate56, the printed web substrate 60 disposed about intermediate parent roll62 can be then processed separately by apparatus for printing andimparting elastic-like behavior 10. The resulting printed and texturedweb substrate 56 can be then wound about an additional second parentroll 54 for storage or, alternatively, directed immediately to anymanufacturing process 58 as required. In any regard, it should berealized by those of skill in the art that the step of applying indicia72 applied to a web substrate 18 by flexographic printing apparatus 64and the step of providing elastic-like behavior to the web substrate 18by apparatus for printing and imparting elastic-like behavior 10 can bepresented as concurrent steps in a singular process or as individualizedsteps as needed by the end user.

Additionally, it should be realized that web substrate 18 of the presentinvention may comprise polyolefins, such as polyethylenes includinglinear low density polyethylene (LLDPE), low density polyethylene(LDPE), ultra low density polyethylene (ULDPE), high densitypolyethylene (HDPE), or polypropylene and blends thereof with the aboveand other materials. Examples of other suitable polymeric materialssuitable for use in the instant invention and for providing acontainment for a plurality of desired consumer product include othersuitable polymeric materials, such as polyester, polyurethanes,compostable or biodegradable polymers, heat shrink polymers,thermoplastic elastomers, metallocene catalyst based polymers, andbreathable polymers. Further, the web substrate 18 of the presentinvention may also comprise a synthetic woven, synthetic knit,non-woven, aperture film, microscopically expanded three-dimensionalformed films, absorbent or fibrous absorbent materials, foam filledcompositions, laminates, and/or combinations thereof. Any non-wovens maybe spun laced, spun bond, melt blown, carded, and/or air-through orcalender bonded. Additionally, material suitable for web substrate 18 ofthe present invention may be cellulose based.

As shown in FIG. 7, suitable consumer products 74 of the instantinvention may include towels, towel substrates, tissues, tissuesubstrates, wipes, disposable diapers, sanitary napkins, as well asother absorbent articles. Additionally, printed and textured websubstrate 56 may be disposed about a plurality of consumer products 74in a manufacturing process 58 that includes flow wrapping, overwrapping, and any other process known to those of skill in the artsuitable for use in binding a plurality of consumer articles into amarketable consumer unit. Such marketable consumer units may contain aplurality of individually wrapped paper toweling, bath tissues, facialtissues, diapers, sanitary napkins, tampons, and the like.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. An apparatus for providing indicia and an elastic-like behavior to aweb substrate, the apparatus comprising: a printing apparatus, saidprinting apparatus comprising: at least one rotatable ink roller; an inksource cooperatively associated and in fluid communication with each ofsaid ink rollers, said ink source providing ink to said respective inkroller; said ink being transferable to said web substrate when said websubstrate is proximate to said ink roller thereby forming a printed websubstrate; and, an apparatus for imparting elastic-like behavior to saidweb substrate, said apparatus for imparting elastic-like behaviorcomprising: a pair of intermeshing rollers, a first of said pair ofintermeshing rollers having a plurality of ridges and correspondinggrooves, and a second of said pair of intermeshing rollers having aplurality of regions of circumferentially extending ridges extending ina spaced relationship about at least a portion of said second of saidpair of intermeshing rollers, each of said plurality of regions ofcircumferentially extending ridges being separated by correspondinggrooves; wherein said apparatus for imparting elastic-like behavior iscapable of imparting an elastic-like behavior on at least a portion ofsaid printed web substrate with a plurality of first regions and aplurality of second regions, a portion of said first regions extendingin a first direction while the remainder of said first regions extend ina second direction perpendicular to said first direction to intersectone another, said first regions forming a boundary completelysurrounding said second regions, said second regions comprising aplurality of raised rib-like elements; and, wherein said plurality offirst regions and said plurality of second regions are in registrationwith said ink disposed upon said web substrate.
 2. The apparatusaccording to claim 1, wherein said first of said pair of intermeshingrollers is a non-patterned grooved roll.
 3. The apparatus according toclaim 2, wherein said second of said pair of intermeshing rollers is apatterned groove roll.
 4. The apparatus according to claim 3, whereinsaid intermeshing rollers produces said rib-like elements in said websubstrate when passed therebetween.
 5. The apparatus according to claim2, wherein said intermeshing rollers leaves portions of said websubstrate unformed when passed therebetween.
 6. The apparatus accordingto claim 1, wherein said pair of intermeshing rollers provide said websubstrate with said second regions substantially surrounded by saidfirst regions.
 7. The apparatus according to claim 1, wherein one ofsaid pair of intermeshing rollers is provided with a plurality of holes,each of said holes being in fluid communication with said ink source. 8.The apparatus according to claim 1, further comprising a rewindingapparatus wherein said rewinding apparatus is disposed after saidprinting apparatus.
 9. The apparatus according to claim 8, wherein saidapparatus for imparting elastic-like behavior is disposed between saidprinting apparatus and said rewinding apparatus.
 10. The apparatusaccording to claim 8, wherein said apparatus for imparting elastic-likebehavior is disposed after said rewinding apparatus.